Tension limiting mechanisms for closure devices and methods therefor

ABSTRACT

According to an embodiment, a device for tightening an article includes a housing having an interior region and a spool positioned within the interior region and rotatable relative thereto. A tightening mechanism is operably coupled with the spool to cause the spool to rotate within the interior region of the housing. A tension member is coupled with the spool and is configured to be tensioned upon rotation of the spool via the tightening mechanism. The device also includes a tension limiting mechanism that allows the tension member to be tensioned via the tightening mechanism until a tension threshold is achieved. After the tension threshold is achieved, further operation of the tightening mechanism does not substantially tension the tension member due to the tension limiting mechanism.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. Pat. No. 14/322,690 filedJul. 2, 2014, entitled “Tension Limiting Mechanisms for Closure Devicesand Methods Therefor,” which claims priority to U.S. Patent ApplicationNo. 61/842,238 filed Jul. 2, 2013, entitled “Tension Limiting Mechanismsfor Closure Devices and Methods Therefor,” the entire disclosures ofwhich are hereby incorporated by reference, for all purposes, as iffully set forth herein.

BACKGROUND OF THE INVENTION

The present invention is related to closure devices for variousarticles, such as braces, medical devices, shoes, clothing, apparel, andthe like. Such articles typically include closure devices that allow thearticle to be placed and closed about a body part. The closure devicesare typically used to maintain or secure the article to the body part.For example, shoes are typically placed over an individual's foot andlace is tensioned and tied to close the shoe about the foot and securethe shoe to the foot. Conventional closure devices have been modified inan effort to increase the fit and/or comfort of the article about thebody part. For example, shoe lacing configurations and/or patterns havebeen modified in an attempt to increase the fit and/or comfort ofwearing shoes. Conventional closure devices have also been modified inan effort to decrease the time in which an article may be closed andsecured about the body part. These modifications have resulted in theuse of various pull cords, straps, and tensioning devices that enablethe article to be quickly closed and secured to the foot.

BRIEF SUMMARY OF THE INVENTION

The embodiments described herein provide closure systems havingmechanisms that limit the tension that may be applied to a tensionmember (e.g., lace) in closing an article. The tension limitingmechanisms may prevent or limit the article from being over-tightened.Additionally or alternatively, in some embodiments the closure systemsmay include a mechanism that functions to substantially maintain atension on the tension member. Stated differently, the closure systemmay include a mechanism that allows the tension member's tension to bereleased or loosened when a sudden spike in tension occurs, such as fromswelling of a limb, dynamic movement of a body part, an impact of thearticle with surrounding objects, and the like. According to one aspect,a reel for use with a lacing system for tightening an article isdescribed. The reel includes a housing having an interior region and aspool positioned within the interior region of the housing and rotatablerelative thereto. The spool has having an annular channel formedtherein. The reel also includes a knob that is rotatable relative to thehousing and operably coupled with the spool to cause the spool to rotatewithin the interior region of the housing. A tension member is coupledwith the spool and is tensioned by winding the tension member around thespool's annular channel upon rotation of the knob, The reel furtherincludes a tension control mechanism that is configured to: enabletensioning of the tension member by rotation of the knob until a tensionthreshold is achieved, after which further rotation of the knob does notcause further tensioning of the tension member; and enable rotation ofthe spool within the housing's interior region upon tensioning of thetension member from a source other than the knob.

According to another aspect, a device for tightening an article isdescribed. The device includes a housing having an interior region and aspool positioned within the interior region of the housing and rotatablerelative thereto. The device also includes a tightening mechanism thatis operably coupled with the spool to cause the spool to rotate withinthe interior region of the housing and a tension member that is coupledwith the spool and configured to be tensioned upon rotation of the spoolvia the tightening mechanism. The device further includes a tensionlimiting mechanism that allows the tension member to be tensioned viathe tightening mechanism until a tension threshold is achieved, afterwhich further operation of the tightening mechanism does notsubstantially tension the tension member.

According to yet another aspect, a method for assembling a device fortightening an article is described. The method includes providing ahousing having an interior region and positioning a spool within theinterior region of the housing so that the spool is rotatable relativeto the housing. The method also includes operably coupling a tighteningmechanism with the spool so that the spool is rotatable within theinterior region of the housing upon operation of the tighteningmechanism. The method further includes coupling a tension member withthe spool so that the tension member is tensionable upon rotation of thespool via the tightening mechanism. The method additionally includesoperably coupling a tension limiting mechanism with the spool to enablethe tension member to be tensioned via the tightening mechanism until atension threshold is achieved, after which further operation of thetightening mechanism does not substantially tension the tension member.

According to yet another aspect, a device for tightening an article isdescribed. The device includes a housing having an interior region and aspool positioned within the interior region of the housing and rotatablerelative thereto. The device also includes a tightening mechanism thatis operably coupled with the spool to cause the spool to rotate withinthe interior region of the housing and a tension member that is coupledwith the spool and configured to be tensioned upon rotation of the spoolvia the tightening mechanism. The device further includes a forcelimiting mechanism that is configured to transfer tightening forces fromthe tightening mechanism to one or more internal components of thedevice until a tightening force threshold is achieved and that isfurther configured to not transfer tightening forces from the tighteningmechanism to the one or more internal components of the device after thetightening force threshold is achieved.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in conjunction with the appendedfigures:

FIG. 1 illustrates a perspective view of a lacing system that may beused for tightening a shoe or other article.

FIG. 2 illustrates a perspective view of another lacing system that canbe used for tightening a shoe or other article.

FIGS. 3 & 4 illustrate exploded perspective views of the lacing systemof FIG. 2.

FIG. 5 illustrates an embodiment of a closure device having a tensionlimiting mechanism that is configured to withstand dynamic lace tensionloading.

FIG. 6 illustrates an embodiment of a closure device having a tensionlimiting mechanism that is configured to slip when dynamic lace tensionloads are applied or experienced.

FIGS. 7A-M illustrate embodiments of closure devices and/or tensionlimiting mechanisms that utilize a wave clutch or similar type clutchcomponent.

FIGS. 8A-II illustrate embodiments of closure devices and/or tensionlimiting mechanisms that utilize decent-like components or mechanisms.

FIGS. 9A-I illustrate embodiments of closure devices and/or tensionlimiting mechanisms that affect a user's grip on a knob portion of theclosure device.

FIGS. 10A-G illustrate embodiments of closure devices and/or tensionlimiting mechanisms that utilize friction-based clutching system.

FIGS. 10H-I illustrate an embodiment of a closure device and/or tensionlimiting mechanism that utilizes a torsion spring to create afriction-based clutching mechanism.

FIGS. 10J-M illustrate an embodiment of a closure device that includes atension level indicator.

FIGS. 11A-C illustrate another embodiment of a closure device having atension control mechanism that includes a pair of radially displaceableclutch components.

FIGS. 12A-E illustrate another embodiment of a closure system having atension limiting component or mechanism.

In the appended figures, similar components and/or features may have thesame numerical reference label. Further, various components of the sametype may be distinguished by following the reference label by a letterthat distinguishes among the similar components and/or features. If onlythe first numerical reference label is used in the specification, thedescription is applicable to any one of the similar components and/orfeatures having the same first numerical reference label irrespective ofthe letter suffix.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments described herein provide various tension limiting mechanismsthat may be used for closure devices and/or other devices. A specificexample of a closure device for which the input force limitingmechanisms may be used are rotary or reel based closure devices thattypically include a knob that is grasped by a user and rotated to windlace around a spool mounted within a housing. The lace is tensioned bythe closure device as the lace is wound around the spool. Tensioning ofthe lace is used to close or tighten apparel, equipment, or some othercomponent that the closure device is coupled with.

These types of closure device are used frequently to closure or tightenvarious apparel and equipment, such as standard footwear, athleticfootwear, medical footwear, and the like. Some uses of these closuredevices require the application of relatively large tension to theclosure device's lace. To provide the relatively large tension forces,some closure devices include gearing that amplifies the input forceapplied by a user. The gearing, however, may allow a user to apply fargreater tension than is required for a given application. For example,in snowboard boots, a geared system may be used to increase the lacetension that may be applied by the closure system. The increased lacetension may be required to completely close and properly tighten one ormore layers of the snowboard boots. The geared system, however, mayallow a user to tighten the lace beyond what would be expected in useand/or beyond a tension that may cause discomfort or pain if the bootsare being worn. If the boots are not fit about a leg, a user mayover-tighten the lace due to neglect, lack of attention, and the like.

Over-tensioning of the lace may damage or break the lace as well asdamage or break internal components of the closure device and/or laceguides around which the lace is wound. Further, when the closure deviceis used to close apparel or equipment about a user's body part,over-tensioning the lace may result in the body part being squeezed tootightly, which may limit or restrict blood flow to and from the bodypart. Such over-tensioning, for example, can be a serious problem fordiabetic patients wearing a brace (e.g., foot brace or boot) becausethese patients often lose sensation or feeling in the body part that isbeing supported by the brace. Loss of blood flow to a body part indiabetic patients can result in serious complications includingamputation of the body part. The embodiments described herein providemechanisms that limit the amount of tension that may be applied to thelace. This is often achieved by limiting the input force that istransferred from the closure device's knob to the spool or othercomponent. As such, a user may not be able to over-tighten the closuredevice, thereby remedying many of the problems associated withover-tensioning a lace. Further, the embodiments described herein alsoallow a repeatable tension to be applied to the lace and thus to thefootwear or other device. Repeatable tensioning as used herein means theability to repeatedly tension the lace to a favorable or desiredsetting, such as to a desired lace tension and/or fit of the footwearabout the body. The embodiments described herein allow a user to easilydon footwear and operate a closure device (e.g., reel assembly) totension the lace until a desired tension is achieved, after which theclosure device will not further tension the lace. In this manner,donning and tensioning of the footwear is greatly enhanced.

Referring briefly now to FIG. 1, illustrated is a perspective view of anembodiment of closure device or system that is used for tightening ashoe. The shoe can be any suitable footwear that can be tightened arounda wearer's foot. The closure device can be used to close or tightenvarious other articles as described herein, such as, for example, abelt, a hat, a glove, snowboard bindings, a medical brace, or a bag. Theclosure device can include a reel assembly 104, a lace 106, and one ormore lace guides 108. In the illustrated embodiment, the reel assembly104 can be attached to the tongue 110 of the shoe, although variousother configurations are also possible. For example, the reel assembly104 can be attached to a side of the shoe, which can be advantageous forshoes in which the shoe sides 112 a-b are designed to be drawn closelytogether when tightened leaving only a small portion of the tongue 110exposed. The reel assembly 104 can also be attached to the back of theshoe and a portion of the lace 106 can pass through the shoe usingtubing for the lace to travel through. In some embodiments the tubingcan be positioned on either side of the wearer's ankle such that thelace 106 can be engaged with the reel assembly 104 when back-mounted. Insome embodiments, the reel assembly 104 may also be attached to thelateral side at or near the top of the lacing throat.

FIG. 2 is a perspective view of an embodiment of a closure device 200that can be similar to the closure device of FIG. 1, or any otherclosure device described herein. The closure device can include a reelassembly 204 which can be similar to the reel assembly 104, or any otherreel/knob assembly described herein. FIG. 3 is an exploded perspectiveview of the reel assembly 204. FIG. 4 is another exploded perspectiveview of the reel assembly 204. The closure device 200 that isillustrated in FIGS. 2-4 represents general reel based closure devicesand illustrates common components of such devices. It should be realizedthat other reel based closure devices may include more or fewercomponents and/or have a modified configuration.

With reference to FIGS. 2 to 4, the reel assembly 204 can include a basemember 214, a spool member 216, and a knob member 218. The base membercan include a spool housing 22.0 and a mounting flange 222. The spoolhousing 220 can include a plurality of ratchet teeth 224, which canextend radially inwardly. The base member 214 can include lace holes(e.g., 226 a) that allow the lace 206 to enter the spool housing 220.

The spool member 216 can be disposed within the spool housing 220 suchthat the spool member 216 is rotatable about an axis 228 with respect tothe spool housing 220. The lace 206 can be secured to the spool member216 such that when the spool member 216 rotates in a tighteningdirection (shown by arrow A) the lace 206 is drawn into the spoolhousing 220 and is wound around the channel 230 formed in the spoolmember 216, and when the spool member 216 rotates in a looseningdirection (shown by arrow B) the lace 206 unwinds from the channel 230of the spool member 216 and exits the spool housing 220 via the laceholes (e.g., 226 a). The spool member 216 can also include spool teeth232 formed thereon. It will be understood that the embodiments disclosedherein can be modified such that rotation in the direction shown byarrow B will tighten the lacing. In this particular embodiment, the knobmember 218 may be raised axially to disengage from spool 230 to allowthe spool to freewheel in direction B in order to release the lace. Inother embodiments, rotation of the knob member 218 in the directionshown by arrow A may loosen the lacing system. In a specific embodiment,the knob member 218 may be rotated be a specific amount (e.g., ¼ to ½turn) in a loosening direction (e.g., as shown by arrow A) to loosen thelacing system. Other user interfaces are possible for tightening,releasing, or adjusting lace tension.

The knob member 218 can be attached to the spool housing 220 such thatthe knob member 218 can rotate about the axis 228 with respect to thespool housing 220. The knob member 218 can include knob teeth 234 thatcan be configured to mate with the spool teeth 232 to couple the knobmember 218 to the spool member 216 such that rotation of the knob member218 in the tightening direction causes the spool member 216 to alsorotate in the tightening direction. In some embodiments, the rotation ofthe knob member 218 in the loosening direction can also cause the spoolmember 216 to rotate in the loosening direction. The knob member 218 canalso include one or more pawls 236 which can be biased radiallyoutwardly so as to mate with the ratchet teeth 224. The pawls 236 andratchet teeth 224 can be configured so that the ratchet teeth 224 candisplace the pawls 236 radially inwardly when the knob member 218 isrotated in the tightening direction, thereby allowing the knob member218 to rotate in the tightening direction. The pawls 236 and the ratchetteeth 224 can also be configured so that they engage one another whenforce is applied to twist the knob member 218 in the looseningdirection, thereby preventing the knob member 218 from rotating in theloosening direction. In other arrangements, the ratchet teeth 224 may beoriented axially to engage knob pawl members (not shown) that arecorrespondingly arranged to mate axially.

Thus, a reel assembly such as reel assembly 204 can provide a one-waytightening system configured to allow a user to rotate the knob member218 in the tightening direction, which causes the spool member 216 torotate in the tightening direction, which in turn causes the lace 206 tobe drawn into the spool housing 220 via the lace holes (e.g., 226 a). Asthe lace 206 is drawn into the spool housing 220 the lacing system 200can tighten, causing the lace guide 208 to be drawn in the directiontoward the reel assembly 204 (shown by arrow C in FIG. 2). Although thelacing system 200 is shown with a single lace guide 208, any othersuitable number of lace guides can be used. Other features of the reeland lacing system are described in U.S. Patent Application No.2011/0266384, filed Apr. 29, 2011, and Titled “Reel Based LacingSystem”, the entire disclosure of which is incorporated herein byreference.

As described above, the embodiments described herein provide mechanismsthat limit the tension that may be applied to a lace via a closuredevice, such as those illustrated in FIGS. 1-4. The mechanisms thatprovide tensioning limits typically include clutching mechanisms orcomponents (hereinafter clutching mechanism) that may be placed withinthe closure device to limit the input force that is transferred from auser to one or more internal components of the closure device. Typicallythe clutching mechanism or component is designed to slip when a desiredmaximum input torque is achieved with the reel assembly—i.e., the lacereaches or attains a certain tension. In some embodiments, the tensionlimit at which the clutching mechanism slips may be set by a user of thedevice. In other embodiments, the tension limit at which the clutchmechanism slips may be predetermined or set by a third-party, such as bya physician or manufacturer.

In many applications the closure device is used in situations where thetension on the lace will be dynamic. For example, when the closuredevice is used to tighten shoes, the tension in the lace will vary asthe user flexes and relaxes their foot, such as due to running, walking,jumping, flexing, and the like. This increase in lace tension is due toconditions other than the user operating the closure device's knob. insuch embodiments, the tension on the lace may increase beyond aninitially set tension threshold—i.e., a maximum tension limit that isset or desired for the closure device and/or clutching mechanism. Insuch instances, it may be desirable for the lace and closure device towithstand the higher tension loads that are placed on the lace in orderto keep the shoe or other device closed. For example, if dynamic loadsare being placed on the lace as a user runs or moves in a sportingevent, it may be desirable to keep the shoe closed and tightened aboutthe user's foot. In such instances, the closure device and clutchingmechanism should be designed to withstand the higher dynamic loads,otherwise the user would have to continually retighten the shoe's lace.In many embodiments, the ability of the closure device to “withstanddynamic lace loading”, and thus maintain a closure of an article, isachieved by preventing the closure device's spool from rotating in adirection that effects loosening of the lace (i.e., a looseningdirection).

In other instances, it may be desirable for the lace and closure deviceto slip when relatively high tension loads are experienced in order toprotect the user and/or device or components. For example, if dynamicloads are applied to the lace of a brace that is being worn by apatient, it may be desirable to allow the brace's lace and closuredevice to slip as the higher dynamic loads are applied. In suchinstances, slippage may keep the pressure applied by the brace to thepatient's body part within a prescribed pressure range, which may reduceor eliminate loss of blood flow to the body part or the formation ofscars or other damage to the body tissue. Slippage of the closure devicein such instances may ultimately reduce damage to the body part and/orimprove healing of the body part. In many embodiments, the ability ofthe closure device to “slip in response to dynamic lace loading” isachieved by allowing the closure device's spool to rotate in a directionthat effects loosening of the lace (i.e., a loosening direction) whenhigher lace tensions are experienced. The embodiments of the closuredevices described herein allow for the lace to withstand higher dynamicloads and/or slip when higher dynamic loads are applied as desired.

In some embodiments, the ability of the closure device and lace towithstand high dynamic loading of the lace, or to slip when higherdynamic loads are applied, may be achieved by varying the placement of astop mechanism that prevents the closure device's spool for rotating inthe loosening direction. In some embodiments, the stop mechanismincludes a pawl mechanism, or pawl teeth, that engage with correspondingteeth of the closure device's housing (or a toothed plate or disc) in aratchet like manner to allow the spool to rotate in a first direction(i.e., tightening direction) while preventing rotation of the spool in asecond and opposite direction (i.e., loosening direction). Positioningof the stop mechanism relative to the clutching mechanism may prevent orallow slippage of the spool (i.e., rotation in the loosening direction)in response to dynamic lace tension loading as desired.

FIG. 5 illustrates one embodiment in which a closure device 500 isconfigured to withstand dynamic lace tension loading. As shown in FIG.5, pawl teeth 506 (i.e., stop mechanism) are positioned such that theyinteract with the spool housing 502 and spool 504. In some embodiments,the pawl teeth 506 may be coupled directly with the spool 504 or beintegral components thereof, while in other embodiments, the pawl teeth506 may be coupled with a pawl disc (not shown) that is in turn coupledwith the spool 504 via a spine, engaged teeth, or some other mechanism.A clutching mechanism 508 is positioned axially above the pawl teeth 506and spool 504. Positioning of the pawl teeth 506 axially below theclutching mechanism 508 allows the closure device 500 to withstanddynamic loading or tensioning of the lace. Stated differently, becausethe pawl teeth 506 are positioned axially below the clutching mechanism508, the slippage of the clutching mechanism 508 and knob 510 does notaffect the interaction of the spool 504, pawl teeth 506, and spoolhousing 502. As such, the pawl teeth 506 hold or maintain the spool'sposition regardless of if dynamic lace loads are applied—i.e., the pawlteeth 506 prevent counter rotation or unwinding of the spool 504.

In some embodiments, a second clutch mechanism (not shown) may be usedto allow slippage of the closure mechanism's spool, but at a tensiongreater than that provided by the clutch mechanism 508 that limits theinput torque or tension. Stated differently, the closure device mayinclude a first clutch mechanism that limits the input torque or tensionapplied by a user, and may include a second clutch mechanism that limitsthe dynamic lace tension loading that may occur. The second clutchmechanism may be configured to clip at a higher lace tension load thanthe first clutch mechanism in order to allow some dynamic lace tensionloading to occur while preventing excessive lace tension loading thatmay damage the lace, closure device components, and/or damage bodilytissue. Accordingly, the user may use the article (e.g., shoe) for anactivity (e.g., walking, running, and the like) without loosening thearticle's lace while being safeguarded from injury or other issues thatmay result from excessive lace tensioning.

In contrast, FIG. 6 illustrates one embodiment in which the closuredevice 600 is configured to slip when higher dynamic lace loads areapplied or experienced. As shown in FIG. 6, the pawl teeth 606 arepositioned such that they interact with the clutching mechanism 608 andspool housing 602. In some embodiments, the pawl teeth 606 may becoupled directly with the clutching mechanism 608 or be integralcomponents thereof, while in other embodiments, the pawl teeth 606 maybe coupled with a pawl disc (not shown) that is in turn coupled with theclutching mechanism 608. The spool 604 is positioned axially below theclutching mechanism 608. In this arrangement, the pawl teeth 606 do notdirectly affect the spool 604. Rather, the pawl teeth 606 indirectlyaffect the spool 604 via the clutch components of clutching mechanism608 (e.g., wave like clutch teeth and the like). Because the clutchcomponents of clutching mechanism 608 are used to hold the spool 604 inposition (i.e., to prevent counter rotation or unwinding), the spool 604will slip when a predetermined input torque is applied by a user and/orwhen the lace's tension level exceeds a threshold amount. In thismanner, the closure device 600's “hold”, or ability to prevent counterrotation, is limited to a predetermined input torque and lace tensionthreshold. As the lace experiences dynamic loading, the spool 604counter-rotates within spool housing 602, which causes the lace tounwind slightly from around the spool thereby releasing or loosening thelace tension to some degree.

The configurations of FIGS. 5 and 6, or configurations similar to theseembodiments, are provided to illustrate how the hold of a closure devicemay be modified based on a usage or need of the device. The remainingembodiments described herein (i.e., FIGS. 7A-11C) may employ similarpawl teeth, spool housing, spool, and/or clutch mechanism configurationsin order to provide a limited or relatively infinite lace hold asdesired. Stated differently, the embodiments of FIGS. 7A-11C may bemodified as desired to allow the closure device to withstand higherdynamic loads or slip when such loads are applied. It should be notedthat the interface between the clutch mechanism and spool in the crosssection view of FIGS. 5-6 is illustrated having a wave likeconfiguration. The wave like configuration is used merely to illustratethe positioning of the clutch/spool interface relative to the stopmechanism. In most embodiments, a cross section of the clutch/spoolinterface will not have a wave like configuration, but rather straightline or toothed configuration. As such, the wave like cross sectionalclutch/spool interface is not physically representative of most of theembodiments described herein and such embodiments are not limited byillustration of FIGS. 5-6.

In other embodiments, the clutching mechanism may be designed to limit auser's input rather than directly limit the tension that may be applied.For example, the clutching mechanism may be configured to allow a userto rotate a knob of the closure device by only a specified amount. Inthis manner, the user's input to the knob is limited rather than theresulting tension that is applied to lace. In this manner, the clutchingmechanism indirectly limits the lace tension that may be applied ratherthan directly limiting the lace tension via slippage of the clutch/spoolinterface. The tension that is ultimately applied to the lace may varydue to differences in a user's body part size, the closure devicecomponent configuration, and the like. In still other embodiments, theclutching mechanisms described herein may provide an audible feedback,tactile feedback, and/or visual feedback to indicate the amount oftension that is applied to lace and/or to indicate that a maximum amountof tension has been applied. In one embodiment, the audible feedbackand/or tactile feedback may involve a clicking sound and/or sensation.The visual feedback may involve various indicators positioned on theknob that visually illustrates an amount of tension applied and/or thata tension limit has been reached. In some embodiments, the feedbackindicator may be positioned on the lace, a knob, a lace guide, and thelike. An indicator positioned on the lace may indicate a relativeposition of the lace with respect to the closure device rather thanindicating an amount of tension applied to lace. These and other aspectsof the tension limiting mechanisms will be more apparent with referenceto the figures described below.

Referring now to FIGS. 7A-M, illustrated are embodiments of clutchingmechanisms that utilize a wave clutch or similar type clutch component.For example, as illustrated in FIGS. 7A-D, a wave clutch mechanism 710may be inserted between a knob 702 and a tension limiter component 703.The tension limiter component 703 may include a top member and a bottommember with a shaft member extending therebetween. The top member ofclutch component 703 may be positioned axially above and/or within arecessed portion of a top surface of knob 702 while the bottom member ispositioned axially below and/or within a recessed portion of a bottomsurface of knob 702. A spring component 718 may be positioned betweenthe top member of tension limiter component 703 and the top surface ofknob 702. The wave clutch mechanism 710 may be positioned between thebottom member of tension limiter component 703 and the bottom surface ofknob 702. Wave clutch mechanism 710 includes a top member 714 that iscoupled with or otherwise integrally formed with the bottom surface ofknob 702 and a bottom member 712 that is coupled with or otherwiseintegrally formed with the bottom member of tension limiter component703.

The top member 714 and bottom member 712 each include teeth that have awavelike or sinusoidal pattern. The wavelike teeth of bottom member 712and top member 714 interact via friction to drive tension limitercomponent 703 as knob 702 is rotated by a user. As the tension in a lace(not shown) that is wound around spool 706 increases, an increasedamount of friction between the wavelike teeth of bottom member 712 andtop member 714 is required to drive spool 706. Eventually the frictionrequired to drive bottom number 712 and spool 706 is sufficient enoughthat the wavelike teeth of bottom member 712 and top member 714 willbeing to slip, thereby preventing further tensioning of the lace. Spring718 biases the top member 714 and bottom member 712 together and may beused to vary the frictional engagement of the teeth. Spring 718 may beremoved and replaced with a stiffer or more flexible spring to bias thetop member 714 and bottom member 712 together in a desired manner andthereby vary the frictional force required to cause slippage of thewavelike teeth, 714 and 712. Replacing the spring 718 in the manner maybe used to increase or decrease the normal force, and thus the frictionforce, between the wave clutch mechanism 710 of top member 714 andbottom number 712. As can be readily understood, increasing ordecreasing the frictional engagement of the top member 714 and bottommember 712 correspondingly increases or decreases the lace tensionthreshold at which the wave clutch mechanism 710 slips, thereby enablingmore or less tension to be applied to the lace.

In some embodiments, a screw 716 may be threaded into a threadedprotrusion 717 of housing 704 to couple the components together. In someembodiments, screw 716 may be accessible to a user to enable the user toremove one or more of the components, such as for repair or replacement.In other embodiments, the screw 716 may only be accessible by aphysician, or other individual, using a specialized tool.

As shown in FIG. 7A, in one embodiment the pawl teeth 713 may bepositioned on an interior surface of the knob 702. The pawl teeth 713may interact with corresponding ratchet teeth 711 that are positioned onan interior surface of the housing 704. This configuration allows thespool 706 and tension limiter component 703 to slip within housing 704.Accordingly, in this configuration embodiment 700 would be unable towithstand dynamic lace tension loads. Instead, embodiment 700 would slipupon the application of dynamic lace tension loads. This configurationwould be ideal for applications involving medical braces and/or anyother application in which slippage due to dynamic tension loads isdesired.

In other embodiments, the pawl teeth 713 may be positioned elsewhere toallow embodiment 700 withstand dynamic lace tension loads. For example,in some embodiments the pawl teeth 713 may be positioned on an outersurface of the spool 706 and configured to interact with correspondingratchet teeth 711 positioned on an interior surface of housing 704. Inthis configuration, embodiment 700 would be able to withstand dynamictension loads that are placed on the lace without slipping. Thisconfiguration would be ideal for applications involving shoes, boots,and other apparel or devices in which slippage due to dynamic tensionloads is not desired.

FIGS. 7E-G illustrate another embodiment of a closure device 720 thatincludes a clutching mechanism. Closure device 720 includes a housing725 and knob 729 as previously described. Positioned on a bottom surfaceof knob 729 and on a top surface of the spool 727 is a tension limitingmechanism 728 (e.g., wave clutch). Tension limiting mechanism 728 mayinclude a wavelike teeth pattern as previously described, or any othertooth pattern described herein, that allows a top and bottom componentof the tension limiting mechanism 728 to slip relative to one anotherwhen a certain input torque and/or lace tension is achieved. A spring726 is positioned on a bottom surface of spool 727 and on a top surfaceof a top cam component 724. Positioned axially below the top camcomponent 724 is a bottom cam component 722. The bottom cam component722 includes a handle portion 721 that may be rotated by a user to causethe top cam component 724 and bottom cam component 722 two axiallyseparate as shown in FIGS. 7F-G. The top cam component 724 and bottomcam component 722 include cam surfaces that causes the components toaxially separate as handle 721 is rotated by a user. A post orprotrusion 723 that is coupled with a bottom surface of housing 725includes a key member that couples with top cam component 724 to preventrotation of the top cam component 724 as bottom cam portion 722 isrotated via handle 721. This allows the cam surfaces of top camcomponent 724 and bottom cam component 722 to cause axial separation ofthe components as the handle portion 721 is rotated by a user. Bottomcam component 722 may include a slot (not numbered) within which the keymember slides as bottom cam component 722 is rotated relative to the topcam component 724.

The axial separation of the top cam component 724 from the bottom camcomponent 722 compresses spring 726 positioned between the top surfaceof top cam component 724 and the bottom surface of spool 727.Compression of spring 726 increases the normal force, and thusfrictional force or engagement, of tension limiting mechanism 728 suchthat tension limiting component 728 is prevented from slipping until agreater input torque and/or lace tension force is achieved. In thismanner, a user is easily able to adjust the tension limiting propertiesor tension slippage threshold of closure device 720.

FIGS. 7H-J illustrate yet another embodiment of a closure device 730comprising a clutching mechanism. Closure device 730 includes a knob734, spool housing 732, and spool 736. The tension limiting mechanism738 is positioned between a top surface of spool 736 and a bottomsurface of knob 734. Tension limiting mechanism 738 may include awavelike tooth pattern and/or any other pattern that allows slippage ofthe top component and bottom component of tension limiting mechanism738. A spring 735 is positioned between the bottom surface of spool 736and spool housing 732. Spring 735 biases spool 736 axially upward toapply a friction force between the bottom component and top component oftension limiting mechanism 738. A screw 737 or other closure componentmay be inserted through knob 734 and spool 736 and coupled with housing732. Screw 737 may be adjusted to compressed spring 735 via tensionlimiting mechanism 738 and spool 736. Compressing spring 735 increasesthe normal force, and thus the frictional force or engagement, betweenthe top component and bottom component of tension limiting mechanism738. In this manner, the input torque and/or lace tension required tocause slippage of the tension limiting mechanism 738 may be varied. Insome embodiments, a bottom portion of housing 732 may be adjusted (e.g.,rotated) to compress spring 735 and thereby vary the normal forcebetween the top and bottom components of tension limiting mechanism 738.In some embodiments, adjusting the bottom portion of the housing 732 maycause the screw 737 to move axially upward or downward and therebycompress spring 735. FIGS. 7I-J illustrate the operation of the tensionlimiting mechanism 738. Specifically, these figures illustrate the topand bottom components of tension limiting mechanism 738 in a fullyengaged position and in a position in which the plates are slippingrelative to one another.

FIGS. 7K-L illustrate another embodiment of a closure device 740 thatincludes a clutching mechanism 748. The closure device 740 of FIGS. 7K-Lis similar to the closure device 730 of FIGS. 7H-J, in that closuredevice 740 includes a knob 744, spool housing 742, spool 746, and springcomponent 743 having a similar arrangement to closure device 730. Insome embodiments, the top surface of spool 746 of closure device 740 mayfunction as the bottom component of tension limiting mechanism 748. Insuch embodiments, the top surface of spool 746 may interact with a topcomponent of tension limiting mechanism 748 to provide slippage of thetwo components when a predetermined input torque and/or lace tensionthreshold is achieved. In some embodiments, the bottom surface of knob744 may function as the top component of tension limiting mechanism 748.

FIGS. 7K-L further illustrate the top component of tension limitingmechanism including pawl teeth (not numbered) that interact withcorresponding ratchet teeth of housing 742. This configuration allowsthe spool 746 to slip when a dynamic load is applied to the lace. Inanother configuration, spool 746 may include the pawl teeth interactwith corresponding ratchet teeth of housing 742. This configurationwould not allow slippage of the spool 746 as a dynamic load is applied.Rather, this configuration would provide an essentially infinite hold ofthe lace regardless of the dynamic lace tension applied.

In some embodiments, closure device 740 may be coupled with apparel or adevice so that access to a bottom of the closure device is provided. Insuch embodiments, a strap 741 may be positioned across the bottomsurface of the closure device 740 and coupled in a closed position overthe bottom surface of closure device 740 via Velcro® or anotherfastening component. Strap 741 may be uncoupled to expose the bottomsurface of closure device 740. Exposing the bottom surface of closuredevice 740 may allow a screw or other fastening component to be adjustedto compresses spring 743 and thereby vary the tension limitingcapability of tension limiting component mechanism 748 as describedherein.

FIG. 7M illustrates another embodiment of a closure device 750 thatincludes a clutching mechanism. As in some of the previous embodiments,closure device 750 includes a spool housing 752, spool 756, knob 754,and tension limiting mechanism 758 positioned between the bottom surfaceof knob 754 and a top surface of spool 756. A spring 755 is positionedbetween a bottom surface of spool 756 and spool housing 752. Spring 755may be compressed as previously described to vary the tension limitingcapabilities of tension limiting mechanism 758. Tension limitingmechanism 758 may be similar to any of the tension limiting mechanismsdescribed herein. In one embodiment, tension limiting mechanism 758includes saw-like teeth that are positioned relative to one another toallow slippage of the teeth. Specifically, the saw-like teeth of tensionlimiting mechanism 758 are configured so that when the knob 754 isrotated in a tightening direction, the angled portions of the saw-liketeeth press against one another. As the tension in the lace isincreased, the angled or ramped portions of the saw-like teeth begin toslide relative to one another such that when a predetermined inputtorque and/or lace tension is achieved, the top teeth will sliderelative to the bottom teeth without further tensioning the lace. As insome of the other embodiments, closure device 750 includes a screw 757or other fastening mechanism that may be adjusted to increase ordecrease the pressure applied to the saw-like teeth of tension limitingmechanism 758. As described previously, adjusting the pressure appliedto the teeth varies the friction force between the teeth and, thus,varies the input torque and/or lace tension that must be achieved inorder to cause slippage of the tension limiting mechanism 758.

Referring now to FIGS. 8A-II, illustrated are embodiments of closuredevices that include clutching mechanisms that utilize detent-likecomponents to allow slippage of the closure device. For example, FIGS.8A-E illustrate an embodiment of a closure device 800 that includes aspool housing 802, a knob 804, and a spool 806. As shown in greaterdetail in FIG. 8E and the cross section A-A of FIG. 8B, positioned on atop surface of spool 806, or integrally formed therewith, is a tensionlimiting component 808 that includes a plurality of notches 805positioned circumferentially around an outer edge of the tensionlimiting component 808. In another embodiment, the notches 805 may bepositioned on a top surface of the tension limiting component 808.

As shown in greater detail in FIGS. 8A and 8E and the cross section B-Bof FIG. 8C, knob 804 includes a plurality of apertures 807 that are eacharranged so as to be positioned axially above one of the notches 805 oftension limiting component 808. Pins 809 may be inserted throughapertures 807 so that a portion of the pin 809 is positioned within anotch 805 of tension limiting component 808. In one embodiment, a distalend of the pin 809 may be positioned within a notch 805 that ispositioned on a top surface of tension limiting component 808. Inanother embodiment, a main body or shaft of the pin 809 may bepositioned within a notch 805 that is positioned on the outer edge oftension limiting component 808. The pins 809 mechanically resistslippage between the knob 808 and the tension limiting component 808 ina detent-like manner. Specifically, the pins 809 remain within thenotches 805 until a predetermined input torque and/or lace tensionthreshold is achieved. After the predetermined input torque and/or lacetension threshold is achieved, the pins 809 deflect radially out of thenotches 805 so that the knob 804 slips relative to tension limitingcomponent 808.

A desired number of pins 809 may be inserted within the apertures 807 inorder to achieve a desired slippage of the knob 804 and tension limitingcomponent 808. For example, when slippage of the closure device 800 isdesired at a relatively low input torque and/or lace tension threshold,only a few pins 809 may be inserted within apertures 807 to lower theoverall mechanical resistance of the closure device 800. In contrast,when slippage of the closure device 800 is desired at a relatively highinput torque and/or lace tension threshold, more pins 809 may beinserted within apertures 807 to increase the overall mechanicalresistance of closure device 800. In some embodiments, the pins 809 maybe provided to a user to allow the user to easily modify the inputtorque and/or lace tension limiting capabilities of the closure device800. In another embodiment, only a physician or third-party may haveaccess to the pins 809 to modify the closure device's input torqueand/or lace tension limiting capabilities. As previously described, thearrangement of the closure device 800's pawl teeth may be selected so asto allow or prevent slippage of the spool 806 upon application of adynamic lace tension loads as desired.

FIGS. 8F-H illustrate another embodiment of a closure device 810 havinga clutching mechanism that functions in a detent-like manner.Specifically, closure device 810 includes a knob 812 having and annularslot 814 within which a flexible ring 816 is placed. Internally mountedwithin closure device 810 and under knob 812 is a tension limitingcomponent 811 that includes a plurality of notches 813. Flexible ring816 includes a plurality of shafts 818 that extend axially downward fromthe bottom surface of flexible ring 816. Shafts 818 are configured to bepositioned within the notches 813 of tension limiting component 811. Aspreviously described, shafts 818 remain within the notches 813 oftension limiting component 811 until a predetermined input torque and/orlace tension threshold is achieved. Shafts 818 are configured to flexradially outward and out of notches 813 when the predetermined inputtorque and/or lace tension threshold is achieved in order to allowslippage of the knob 812 relative to tension limiting component 811.

Knob 812 includes a plurality of drive components or keys 817 that pressagainst corresponding drive components 815 of the shafts 818 in order todrive flexible ring 816 and tension limiting component 811 as knob 812is rotated by a user. In some embodiments the drive components 817 mayinclude rectangular members that extend axially downward and radiallyinward from knob 812. As shown in FIG. 8H, the corresponding drivecomponents 815 of the shafts 818 may also be rectangular shaped membersthat are insertable between two drive components 817 of knob 812. Thedrive components 815 of the shafts 818 may be positioned on an upper endof the shafts to allow a lower end of the shafts 818 to flex radiallyoutward and into and out of the notches 813. As also shown in FIG. 8H, adiameter of the shafts 818 may be varied to increase or decrease thestiffness of the shafts. For example, flexible ring 816 may includerelatively large diameter shafts 818 a, relatively small diameter shafts818 c, or mid-diameter shafts 818 b. The large diameter shafts 818 a maybe stiffer than the mid-diameter shafts 818 b and small diameter shafts818 c, which may allow a greater input torque and/or lace tension to beapplied before the flexible ring 816 and knob 812 slip relative totension limiting component 811. A user may select the appropriateflexible shaft 816 to achieve a desired input torque and/or lace tensionthreshold before slippage of the knob 812 and tension limiting component811.

FIGS. 8I-L illustrate another embodiment of a closure device 820 havinga clutching mechanism that functions in a detent-like manner.Specifically, knob 822 of closure device 820 includes a plurality ofapertures 827 through which a U-shaped spring 828 is inserted. U-shapedspring 828 includes a pair of inwardly disposed shaft portions 826 thatare configured to fit within notches 823 of a tension limiting member821, which is disposed within closure device 820. The U-shaped spring828 is inserted through apertures 827 until the inwardly disposed shaftportions 826 fit within the notches 823 of the tension limiting member821. The inwardly disposed portions 826 of U-shaped spring 828 are usedto drive the tension limiting member 821 as knob 822 is rotated by auser. As the tension of the lace of closure device 820 is increased, theU-shaped spring 828, and specifically the inwardly disposed shaftportions 826, begins to flex radially outward. Upon achieving orexceeding a predetermined input torque and/or lace tension threshold,the inwardly disposed shaft portions 826 flex radially outwardsufficiently such that the inwardly disposed shaft portions 826 slideout of the notches 823 and the knob 822 slips relative to the tensionlimiting member 821.

FIG. 8L illustrates that the diameter of the tension limiting member828's shaft may be varied 828 a-c so as to vary the spring force thatpresses the inwardly disposed shaft portions 826 into notches 823. Inthis manner, the input torque and/or lace tension limiting capabilitiesof the closure device 820 may be varied by selecting an appropriatetension limiting member 828 a-c. For example, the tension limitingmember 828 may be replaced with a stiffer or more flexible tensionlimiting member 828 a-c as desired to achieve a desired amount ofslippage between the knob 828 and tension limiting member 828.

Referring now to FIGS. 8M-O, illustrated is another embodiment of aclosure device 830 that includes a clutching mechanism that functions ina detent-like manner. Specifically, closure device 830 includes a capmember 838 that includes a plurality of protrusions 836 that protruderadially inward from and are positioned circumferentially around aninner surface of cap member 838. The protrusions 836 are configured tobe positioned within notches 833 of a disc 831. The interaction of theprotrusions 836 and notches 833 drive the disc 831 when the cap member838 is rotated by a user, which in turn drives a spool and tensions thelace. Similar to the embodiments previously described, when the inputtorque and/or lace tension of closure device 830 reaches a predeterminedthreshold, the protrusions 836 flex and/or displace out of the notches833 of disc 831 such that the cap member 838 slips relativity disc 831(see FIG. 8O).

As shown in FIG. 8N, in one embodiment the cap member 838 may bepositioned over a knob 832 a of closure device 830. In this embodiment,the knob 832 a would function as the disc 831 and include the notches833. In such embodiments, a cap member 838 could be selected based onthe stiffness of the protrusions 836 and used with knob 832 a toappropriately tension the lace to near a desired tension threshold. Inother embodiments, the cap member 838 may be positioned internallywithin closure device 830 and an external knob 832 b may be rotated torotate cap member 838 and disc 831.

Referring now to FIGS. 8P-R, illustrated is another embodiment ofclosure device 840 that includes a clutching mechanism. In thisembodiment, a knob 842 includes a plurality of notches 843 within whichball bearings 848 are positioned. The hall bearings 848 are used todrive a disc 845 as knob 842 is rotated. Disc 845 includes one or moreslots 841 that are configured to receive the ball bearing 848. Anadjustable spring plate 846 is positioned between the disc 845 and theknob 842. Adjustable spring plate 846 includes a plurality of arms 847that each have a channel formed therein within which a respective ballbearing 848 is positioned.

The adjustable spring plate 846 is rotatable relative to disc 845 tomove the ball bearing 848 within the channel of arm 847 between a distalend 849 a and a proximal end 849 b. The arm 847 is coupled with a bodyportion of adjustable spring plate 846 in a cantilever like manner withthe proximal end 849 b integrally formed with, or otherwise rigidlycoupled to, the body portion of the spring plate 846 while the distalend 849 a is free-floating or otherwise unconnected to the body portionof adjustable spring plate 846. Varying the position of the ball bearing848 between the distal end 849 a and the proximal end 849 b of arm 847varies the lever or moment arm, which varies the force required todeflect the ball bearing 848 out of one of the notches 843 of knob 842.For example, the lever/moment arm is increased as the ball bearing 848is moved toward the distal end 849 a, which increases the bending momentthat is induced in the arm 847 by a force applied to the ball bearing848. The increased bending moment allows the ball bearing 848 to moreeasily deflect out of one of the notches 843 in response to an appliedforce. In contrast, the lever/moment arm is decreased as the ballbearing 848 is moved toward the proximal end 849 b, which decreases thebending moment that is induced in the arm 847 by a force applied to theball bearing 848. The decreased bending moment requires an increasedforce to be applied to the ball bearing 848 to deflect the ball bearing848 out of one of the notches 843. Stated differently, the arm 847flexes more as the ball bearing 848 is moved closer to the distal end849 a, which allows the ball bearing 848 to more easily deflect out ofone of the notches 843 in response to an applied force.

The arms 847 of adjustable spring plate 846 allows the ball bearings 848to deflect radially inward when a predetermined input torque and/or lacetension threshold is achieved or exceeded, which allows the knob 842 toslip relative to disc 845. In this manner, adjustment of the adjustablespring plate 846, and thus the position of the ball bearings 848relative to arm 847, varies the slippage of the knob 842 relative todisc 845. In some embodiments, when the ball bearings 848 are positionedat the proximal end 849 b of the arms 847, inward deflection of the ballbearings 848 may be prevented thereby preventing slippage of the knob842 relative to disc 845. In this manner, the slippage of the closuredevice 840 may be varied between essentially no slippage and slippage ata relatively low input torques and/or lace tension thresholds asdesired.

In some embodiments, a top portion of the adjustable spring plate 846may be accessible via an aperture of knob 842 to allow a user to rotatethe adjustable spring plate 846 relative to knob 842 and disc 845 andthereby adjust the input torque and/or lace tensioning limitcapabilities of closure device 840.

Referring now to FIGS. 8S-V, illustrated is another embodiment of aclosure device 850 that includes a clutching mechanism. Specifically, aknob 852 of closure device 850 includes a plurality of protrusions 853that extend axially downward from a bottom edge of knob 852. Theprotrusions 853 are configured to be positioned within notches 856 of atension limiting component 854 that is assembled axially below anddirectly adjacent knob 852. The protrusions 853 drive tension limitingcomponent 854 as knob 852 is rotated by a user. Tension limitingcomponent 852 in turn drives the other internal components of theclosure device 850, such as the spool (not numbered), a pawl disc (notnumbered), lace (not shown), and the like. Similar to the otherembodiments described herein, when the input torque and/or lace tensionthreshold is achieved or exceeded, the protrusions 853 of knob 852 willslip from the notches 856 of tension limiting component 854 to preventfurther tensioning of the lace. In some embodiments, a screw 858 orother fastening mechanism may be axially displaceable to adjust africtional engagement or force between the protrusions 853 and notches856 and thereby vary the slippage of the knob 852 relative to tensionlimiting component 854. A spring 857 may be positioned internallybetween the knob 852 and tension limiting component 854. The spring 857may be compressed as screw 856 is axially adjusted to vary thefrictional force/engagement of the protrusions 853 and notches 856. Theprotrusions 853 and/or notches 856 may have a wavelike pattern, sawlikepattern, triangular pattern, and the like as desired. As shown in FIG.8T, in some embodiments the knob 852 may include “windows” or cut outportions that are positioned axially above the protrusions 853. Thewindows may allow the protrusions 853 to more easily deflect axiallyupward and out of the notches 856 of tension limiting component 854.

FIGS. 8W-Y illustrate another embodiment of the closure device 860 thatincludes a clutching mechanism. Specifically, closure device 860includes an outer knob 862 that is axially adjustable relative to aninner knob 868 in order to vary a frictional engagement or force exertedbetween the inner knob 868 and a tension limiting component 864. Tensionlimiting component 864 includes a plurality of notches 863 that arepositioned circumferentially around an outer edge of tension limitingcomponent 864. The inner knob 868 includes inwardly directed protrusions(not shown) or other components that fit within the notches 863 oftension limiting component 864.

As shown in FIGS. 8X-Y, as the outer knob 862 is adjusted axiallydownward relative to inner knob 868, the protrusions or other componentsof inner knob 868 are pressed more firmly within the notches 863 oftension limiting component 864. This increases the frictional engagementor force between the inner knob 868 and tension limiting component 864,and thus increases an input torque and/or lace tension threshold that isrequired to achieve slippage between these two components. Likewise, asthe outer knob 862 is adjusted axially upward relative to inner knob868, the protrusions or other components of inner knob 868 are pressedless firmly within notches 863 of tension limiting component 864, whichallows the inner knob 868 to more easily slip relative to tensionlimiting component 864. In some embodiments, axial adjustment of theouter knob 862 relative to the inner knob 868 may be achieved via athreaded shaft 865 or other component. A user may rotate the threadedshaft 865, such as via a screwdriver or other device, to axially adjustthe outer knob 862 relative to the inner knob 868 and thereby vary theinput torque and/or lace tension limiting capabilities of closure device860.

Referring to FIGS. 8Z-CC, illustrated is another embodiment of a closuredevice that may be used to limit the amount of tension applied to alace. Closure device 870 includes a clutch plate 878 that is positionedbetween a knob 872 and a spool 874. Spool 874 includes a plurality ofnotches 873 within which corresponding teeth 871 of clutch plate 878 arepositioned. Knob 872 includes a plurality of drive components 877 thatare insertable within corresponding keyed portions 879 of clutch plate878 and that function to drive the clutch plate 878 as knob 872 isrotated by a user. As the knob 872 and clutch plate 878 are rotated,teeth 871 drive spool 874 via notches 873. When a predetermined inputtorque and/or lace tension threshold is achieved or exceeded, the teeth871 deflect axially upward and slip out of the notches 873 causing theclutch plate 878 and knob 872 to slip relative to spool 874.

A screw 875 or other component is threadingly coupled with knob 872 soas to be axially adjustable downward onto clutch plate 878. Threadingscrew 875 axially downward onto clutch plate 878 causes clutch plate 878to bow which deflects teeth 871 partially out of notches 873 of spool874. Deflection of the teeth 871 out of notches 873 varies the slippageof the clutch plate 878 and knob 872 relative to spool 874 by allowing alesser input torque and/or lace tension threshold to be achieved beforethe teeth 871 will deflect axially upward and slip out of notches 873.As can be readily understood by one skilled in the art, the more thatclutch plate 878 is caused to bow via screw 875, the more slippage willbe achieved between clutch plate 878 and knob 872 relative to spool 875at a lower input torque and/or lace tension threshold. In someembodiments, clutch plate 878 may include a central aperture and orradially extending slots to facilitate bowing of the clutch plate 878 asscrew 875 is threaded axially downward onto clutch plate 878.

Referring to FIGS. 8DD-II, illustrated is another embodiment of aclosure device 880 that may be used to limit the amount of tensionapplied to a lace. Closure device 880 includes a knob 882 having one ormore radially inwardly extending flanges 881 that are positioned overarms 885 of a clutch plate 888. The position of the flanges 881 relativeto the arms 885 may be adjusted to vary an input torque and/or lacetension threshold at which the closure device 880 will slip.Specifically as shown in cross section A-A of FIG. 8FF and cross sectionB-B of FIG. 8GG, the arms 885 include tab portions 887 that areinsertable within notches 884 of a tension limiting component 886 thatis in turn coupled with a spool (not numbered) or integrally formedtherewith. As described herein, the tab portions 887 are configured todrive rotation of the tension limiting component 886 and spool, and todeflect out of the notches 884 in a detent-like manner when apredetermined input torque and/or lace tension threshold is achieved orexceeded to prevent further tensioning of the lace.

As shown in the cross-sections A-A and B-B, the flanges 881 are slidablealong the arms 885 between a proximal end, in which the flanges 881 arepositioned away from the tab portions 887, and a distal end, in whichthe flanges 881 are positioned adjacent or axially above the tabportions 887. When the flanges 881 are positioned near the proximal end,the flex of the arms 885 is increased due to an increase moment arm andbending moment, which allows the tab portions 887 to more easily deflectout of the notches 884 of tension limiting component 886. In contrast,when the flanges 881 are positioned near the distal end, the flex of thearms 885 is greatly decreased due to a decreased moment arm and bendingmoment, which requires an increased input torque and/or lace tensionforce to cause the tab portions 887 to deflect out of the notches 884.In some embodiments, the flanges 881 may be positioned axially above thetab portions 887 to prevent the tab portions 887 from deflecting out ofthe notches 884. In this manner, slippage of the closure device 880 maybe essentially prevented.

In some embodiments, movement of the flanges 881 along the arms 885 maybe provided via an tension varying mechanism 883, such as a screw thatis threadingly coupled with the clutch plate 888. The tension varyingmechanism 883 may be accessible by a user and/or physician as desired.The tension varying mechanism 883 allows the slippage of the closuredevice 880 to be varied between essentially no slippage and slippage atrelatively low input torques and/or lace tension thresholds as desired.As shown in FIG. 8II, in some embodiments spacers 889 may be positionedbetween the clutch plate 888 and the knob 882 to position and maintainthe flanges 881 at a desired position relative to arms 885. In someembodiments, the spacers 889 and/or tension varying mechanism 883 maydrive rotation of the clutch plate 888 as the knob 882 is rotated by auser.

Referring now to FIGS. 9A-I, illustrated are embodiments of limiting anamount of tension that may be applied by affecting a user's grip on aknob portion of the closure device. For example, FIGS. 9A-B illustratean embodiment of the closure device 900 where a knob component 902includes an inner knob 904 and an outer knob 906. The inner knob 904 isaxially adjustable relative to outer knob 906 so as to increase a gripsurface of the knob component 902. In one embodiment, the inner knob 904may be threadingly coupled with the outer knob 906 such that the innerknob 904 may be threaded axially upward or downward with respect outerknob 906. When the inner knob 904 is threaded fully axially downward,the grip surface of knob component 902 may have a height ofapproximately X as shown in FIG. 9A. In contrast, when the inner knob904 is threaded fully axially upward, the grip surface of knob component902 may have a height of approximately X+Y as shown in FIG. 9B. Becausethe overall grip of the knob component 902 is greater when the innerknob 904 is axially extended from outer knob 906, a user may more easilygrip knob component 902 and rotate the knob component 902 to tension theclosure device's lace. Similarly, when the inner knob 904 is retractedwithin the outer knob 906, a user's grip on knob component 902 isnegatively affected making it more difficult for the user to grip knobcomponent 902 and tension the closure device's lace. In someembodiments, the inner knob 904 may be axially adjustable along a shaft908 that is centrally positioned within closure device 900.

Referring now to FIGS. 9C-F, illustrated is another embodiment of aclosure device 910 in which a user's ability to grip a knob 914 may bevaried. Specifically, an outer cap 912 is positioned atop knob 914. Auser presses radially inward on a cover portion of outer cap 912 whichsqueezes knob 914 and allows the user to rotate knob 914. Outer cap 912includes an adjustment mechanism 915, such as a threaded screw, that maybe adjusted (e.g., rotated) to axially adjust a disc 916 positionedwithin outer cap 912. Axially adjusting disc 916 within outer cap 912varies the user's ability to squeeze the cover portion of outer cap 912about knob 914. For example, when disc 916 is positioned adjacent aninner surface of outer cap 912, the cover portion of outer cap 912 isflexible and may be easily squeezed by a user against the outer surfaceof knob 914. When disc 916 is axially adjusted downward so that disc 916is adjacent a top surface of knob 914, the cover portion of outer cap912 is relatively rigid thereby making it more difficult for a user tosqueeze the cover portion of outer cap 912 against knob 914. In thismanner the ability of a user to grip knob 914 may be varied whichaffects the user's ability to tension a lace via closure device 910and/or allows outer cap 912 to slip relative to knob 914,

Referring now to FIGS. 9G-I, illustrated is another embodiment of theclosure device 920 the may be used to affect a user's ability to grasp aknob component 922 of the closure device 920. Similar to the closuredevice 900 described previously, the knob component 922 of closuredevice 920 includes an outer knob 923 and an inner knob 924. Outer knob923 is rotatable relative to enter knob 924 so as to very a grip surfaceof the knob component 922. For example, when outer knob 923 is adjustedfully axially downward relative to inner knob 924, a grip surface ofknob component 922 may have a height of approximately X as shown in FIG.9G. When outer knob 923 is adjusted fully axially upward relative toinner knob 924, a grip surface of knob component 922 may have a heightof approximately X+Y as shown in FIG. 9H. As previously described, theincreased grip surface of knob component 922 may make it considerablyeasier for a user to grip the knob component 922 and tension the closuredevice's lace. As shown in FIG. 9I, in some embodiments a tool 926 maybe used to hold inner knob 924 stationary relative to outer knob 923 inorder to allow the outer knob 923 to be rotated relative to inner knob924. In other embodiments, tool 926 may be used to provide additionaltorque that may be required to rotate outer knob 923 relative to innerknob 924. In some embodiments, a pair of tools similar to tool 926 maybe used to hold one of the knobs stationary while the other knob isrotated in order to axially adjust the outer knob 923 relative to theinner knob 924.

Referring now to FIG. 10A, illustrated is an embodiment of a closuredevice 1000 that includes a clutching mechanism 1006. Clutchingmechanism 1006 functions via friction between a bottom surface of knob1002 and a top surface of a tension limiting member 1004. Specifically,the bottom surface of knob 1002 and the top surface of tension limitingmember 1004 are angled and these angled portions of the knob 1002 andtension limiting member 1004 engage to effect tensioning of the lace viafriction. Closure device 1000 also includes a screw 1008 or otherfastening component that is coupled with knob 1002. Positioned between abottom surface of screw 1008 and within a recess of knob 1002 is aspring washer 1007. Screw 1008 may be adjusted axially relative to knob1002 so as to compress spring washer 1007. Screw 1008 is also connectedto tension limiting member 1004 such that compression of the springwasher 1007 causes increased engagement or contact, and thus friction,between the angled portions of the knob 1002 and tension limiting member1004. In this manner, the friction force between the knob 1002 andtension limiting member 1004 may be increased or decreased as desired toaffect tensioning of the closure device 1000's lace.

Further, as shown in FIG. 10A, the angle of the knob 1002 and thetension limiting member 1004 may be modified as desired to increase ordecrease the friction between the knob 1002 and tension limiting member1004. For example, increasing the angled portions to have a steeperprofile typically increases the friction between the two componentswhile decreasing the angled portions typically decreases the frictionbetween the two components. In operation, the frictional force betweenthe angled portions of the knob 1002 and tension limiting member 1004drives rotation of the tension limiting member 1004 as the knob 1002 isrotated. The spool 1009 is rotated to wind lace via teeth between thespool 1009 and tension limiting member 1004. When the input torqueand/or lace tension reaches a predetermined threshold, the frictionalforce between the angled portions of the knob 1002 and tension limitingmember 1004 is insufficient to cause further rotation of the spool 1009,which causes the tension limiting member 1004 to slip upon subsequentrotation of the knob 1002. In this manner, the lace may be tensioned toa predetermined threshold before the lace is no longer tensionable viarotation of the knob 1002.

Referring now to FIGS. 10B-D, illustrated is an embodiment of a closuredevice 1010 that includes another embodiment of a friction-basedclutching system. Specifically, closure device 1010 includes a knob 1012and a tension limiting component 1014. A friction disc 1016 ispositioned between the knob 1012 and the tension limiting component1014. The tension limiting component 1014 includes a groove or channelwithin which the disc 1016 is positioned. Frictional contact between thedisc 1016, tension limiting component 1014, and knob 1012 drivesrotation of these components as the knob 1012 is rotated by a user.Closure device 1010 may also include an adjustable spring (not shown)that may be adjusted to increase or decrease the frictional engagementor contact between the knob 1012, disc 1016, and or tension limitingcomponent 1014, and thereby increase or decrease a slippage threshold ofthese components. In some embodiments, disc 1016 may be integrallyformed with knob 1012 so that the closure device 1010 only includes twocomponents (i.e., knob 1012 and tension limiting component 1014).

As described previously, the frictional engagement/force between theknob 1012, disc 1016, and/or tension limiting component 1014 allowstensioning of the closure device 1010's lace until a predetermined inputtorque and/or lace tension threshold is achieved. After thepredetermined input torque and/or lace tension threshold is achieved,one or more of these components (i.e. knob 1012, disc 1016, and/ortension limiting component 1014) will slip so that further tensioning ofthe lace is not possible or is greatly reduced.

FIG. 10D illustrates other embodiments of disc 1016. In sonicembodiments, the frictional disc may be relatively flat 1016 a,conically shaped 1016 b, have multiple conical sections 1016 c, and/orhave any other desired configuration so as to provide a desired amountof frictional engagement/contact between the knob 1012, disc 1016,and/or tension limiting component 1014. Likewise, the material of thedisc 1016 may be varied (e.g., polymer material, metal material, and thelike) to vary the coefficient of friction and thereby provide a desiredamount of frictional force. Depending on the activity or other use ofthe closure device 1010, disc 1016 may be replaced with an appropriatedisc having desired frictional properties for a given activity or usage.

FIGS. 10E-G illustrate another embodiment of a closure device 1020 thatincludes a friction-based clutching system. Specifically, closure device1020 includes a knob 1022 having a channel 1024 formed in its topsurface. A friction ring 1026 may be placed within the channel 1024 ofknob 1022. Closure device 1020 also includes a tension limiting member1028 that is positioned internally of the knob 1022. The friction ring1026 includes a pair of axially extending flanges 1027 that contact thetension limiting member 1028 as the knob 1022 is rotated. Knob 1022 isconfigured to drive rotation of friction ring 1026 as the knob 1022 isrotated by a user. To drive rotation of the friction ring 1026, knob1022 may include a pair of slots 1021 within which radially extendingflanges 1023 of friction ring 1026 are inserted. In some embodiments,tension limiting member 1028 includes a cam surface 1029 that increasesthe frictional contact between the flanges 1027 and the tension limitingmember 1028 as the knob 1022 and friction ring 1026 are rotated relativeto tension limiting member 1028.

The frictional engagement/contact between the friction ring 1026 andtension limiting member 1028, and more specifically engagement/contactbetween the flanges 1027 and cam surface 1029, causes rotation of thetension limiting member 1028 and a spool (not numbered) coupledtherewith, which in turn winds lace around the spool. When apredetermined input torque and/or lace tension threshold is achieved orexceeded, the frictional force between the flanges 1027 and the camsurface 1029 is overcome such that the friction ring 1026 and flanges1027 slip relative to tension limiting member 1028 and cam surface 1029.In this manner, the lace may be tensioned only until a predeterminedinput torque and/or lace tension is approximately achieved. The frictionring 1026 may be removed from knob 1022 and replaced with a differentfriction ring in order to achieve more or less frictional resistance asdesired. Friction ring 1026 may include any number of flanges 1027, anyflange thickness or width, and/or any material to provide a desiredamount of friction.

As shown in FIGS. 10H-I, illustrated is another embodiment of a closuredevice 1030 that uses a friction-based clutching mechanism.Specifically, closure device 1030 includes a knob 1032 and a tensionlimiting component 1036 that is positioned internally of the knob 1032.A coil spring 1038 is positioned between a bottom surface of the knob1032 and a top surface of the tension limiting component 1036. The coilspring 1038 is loosely coiled around a post 1034 of spool housing 1033.The bottom surface of the knob 1032 includes a coupling member 1035 thatan end of the coil spring 1038 attaches to. Similarly, a top surface ofthe tension limiting component 1036 also includes a coupling member 1037that an opposite end of the coil spring 1038 attaches to. As the knob1032 is rotated, the torque is transferred through coil spring 1038 andto the tensioning limiting component 1036 via coupling members 1035 and1037. The torque causes the tension limiting component 1036, and a spool(not numbered) coupled therewith, to rotate, which winds lace around thespool. As the tension in the lace increases, the coil spring 1038 beginsto constrict about the post 1034. At some point during rotation of theknob 1032, such as when a predetermined amount of input torque and/orlace tension threshold is achieved or exceeded, the coil spring 1038will constrict about the post 1034 such that further rotation of thetension limiting component 1036 and knob 1032 is prevented. In thismanner, the lace may be tensioned only until a predetermined amount ofinput torque and/or lace tension threshold is achieved.

Referring now to FIGS. 10J-M, illustrated is an embodiment of a closuredevice 1040 that includes a tension level indicator. Closure device 1040includes a knob 1042. and a tensioning component 1044 that is similar tothe components previously described. A coil spring 1046 is positionedbetween a bottom surface of the knob 1042 and a top surface of thetensioning component 1044. Coil spring 1046 is different than the coilspring 1038 previously described, in that rotation of the knob 1042causes the coil spring 1046 to uncoil rather than constrict about apost. As previously described, torque is transferred from knob 1042 totensioning component 1044 via coil spring 1046. As the input torqueand/or lace tension increases, coil spring 1046 will begin to uncoil.

In some embodiments, one end of the coil spring 1046 may be coupled witha visual indicator that is positioned under a tensioning window 1048 ofknob 1042. Uncoiling of the coil spring 1046 causes the visual indicatorto rotate within the tensioning window 1048, which produces a visualindication of the tension level applied to the lace. In anotherembodiment, one end of the coil spring 1046 may be coupled with acomponent that is configured to rotate past a sensor as the coil spring1046 uncoils. Closure device 1040 may be configured to alert a user whencomponent 1041 rotates past the sensor. The alert may be a visual and/oraudio alert as desired, such as an audible alarm or a flashing lightthat indicates that a predetermined input torque and/or lace tensionthreshold has been reached. In this manner, a user may recognize whenthe closure device 1040's lace has been appropriately tensioned.

As shown in FIGS. 11A-C, illustrated is another embodiment of a closuredevice 1100 that includes a clutch or tension control mechanism. In someembodiments, device 1100 may be used to control the amount of torquethat may be input or transferred to internal components of a closuresystem. Over-torqueing internal components of a closure device or systemcan lead to breakage of one or more of the internal components. Toalleviate this problem, the internal components of closure systems areoften designed and manufactured as relatively robust components. Stateddifferently, the components are designed and manufactured larger thanneeded merely to ensure that the components can handle the stress and/orfatigue associated with over-torqueing (i.e., the transfer of too muchrotational stress to the internal components). Because device 1100 canreduce or prevent issues associated with over-torqueing, the componentsof closure systems can be designed and manufactured smaller than thecomponents currently used, which may allow the closure system to exhibitimproved performance and/or have a smaller size and profile.

Device 1100 is able to reduce or prevent issues associated withover-torqueing by using clutch components 1106 as described hereinbelow. An advantage of the clutch components 1106 is that the componentsare configured or designed to work with conventional closure devicesystems. For example, the clutch components 1106 operably couple withspring 1108, which is a spring that is commonly used in conventionalclosure device systems. In the conventional closure systems, spring 1108may function as the open and close mechanism that allows the system tobe fully opened to release or loosen tension on the system's lace. Insuch embodiments, spring 1108 may expand and contract around a bushingto hold or maintain the closure system in an open configuration. Theclutch components 1106 have a relatively low profile or configurationthat allows the components 1106 to fit within an existing void or cavityof conventional closure systems. Further, the clutch components 1106prevent or limits over-torqueing issues regardless of how the closuresystem's knob or tightening mechanism is rotated. Stated differently,the clutch components 1106 prevent over-torqueing when the closuresystem's knob is rotated in a tightening direction (e.g., clockwise) andwhen the knob is rotated in a loosening direction (e.g.,counterclockwise). Exemplary closure systems in which the clutchcomponents 1106 may be used are further described in U.S. patentapplication Ser. No. 11/263,253, filed Oct. 31, 2005, entitled “ReelBased Closure System,” and U.S. patent application Ser. No. 13/098,276,filed Apr. 29, 2011, entitled “Reel Based Lacing System,” the entiredisclosures of which are incorporated by reference herein.

Referring again to FIGS. 11A-C, device 1100 includes a housing 1102having an interior region within which one or more components of thedevice are positioned. Housing 1102 also includes a pair of lace ports1112 through which lace (not shown) is inserted. A spool 1104 ispositioned within the interior region of housing 1102. Spool 1104 is asimple representation of the internal components of a closure system andis not necessarily illustrative of all the internal system componentsthat may be included. For example, closure systems often include a stopmechanism, such as a pawl disc or component, which is not illustrated inFIGS. 11A-C. Exemplary internal closure system components are describedin U.S. application Ser. No. 11/263,253 and U.S. application Ser. No.13/098,276 incorporated by reference herein above. The inclusion ofspool 1104 is to represent such various internal mechanisms orcomponents (e.g., stop mechanism and the like) of a closure system.

Spool 1104 includes an annular channel or recess 1122 around which thelace is wound as the device 1100 is operated by a user. Spool 1104includes a central protrusion or bushing 1126 about which a spring 1108is positioned. Spring 1108 includes two straight opposing ends that abutopposing planar surfaces of central protrusion 1126. The midsection ofspring 1108 extends from the opposing straight ends in a semicircular oroval-like fashion. The midsection of spring 1108 is positioned betweentwo pins 1150 and an opposing wall or axial protrusion 1124 of spool1104 (see FIG. 11C), which function to hold the spring 1108 in positionas the spring flexes radially inward and outward during operation of thedevice 1100.

A pair of clutch components 1106 are positioned atop spool 1104 andpositioned on opposing sides thereof. Clutch components 1106 eachinclude a central channel 1136 which is positioned atop a correspondingtrack 1128 of spool 1104. The tracks 1128 extends radially from thecentral protrusion 1126 and function to guide the clutch component 1106in moving radially inward and outward during operation of the device1100. The tracks 1128 also function to transfer rotational forces fromthe clutch components 1106 to the spool 1104 when a knob 1110 is rotatedby a user. When the clutch components 1106 are positioned on top of thespool 1104, the spring 1108 is positioned on a top surface of the clutchcomponents and within a channel or groove 1132. The spring 1108 biasesthe clutch components 1106 radially outward relative to spool 1104. Thespring 1108 ensures that teeth 1134 of the clutch components 1106 arebiased toward an engaged position with corresponding teeth 1146 of theknob component 1110, which is positioned atop and coaxially aligned withthe housing 1102, spool 1104, and clutch components 1106.

Knob 1110 includes a central aperture 1144 through which a couplingcomponent, such as a screw and the like, may be positioned to couple thevarious components of the device 1100 together. Knob 1110 also includesan outer surface 1142 that is configured to be gripped by a user. Theouter surface 1142 may include a textured configuration that increasesthese friction between a user's hand and the knob 1110 or may includeone or more materials, such as rubber, plastic, and the like, thatincreases the frictional resistance between the user's hand and the knob1110. In some embodiments, the frictional material may be included as anover mold that is coupled with the knob 1110.

FIG. 11B illustrates a top and cross-sectional view of the assembledcomponents of device 1100. FIG. 11C illustrates the device 1100 duringoperation. Specifically, as shown in the top view of FIG. 11C, with theteeth 1134 of clutch component 1106 engaged with the corresponding teeth1146 of the knob 1110, rotation of the knob 1110 causes the spool 1104to rotate via clutch components 1106 and tracks 1128. As the lace istensioned via rotation of the spool 1104, the tension in the lace beginsto counteract the rotational force input to knob 1110 by a user. Asshown in the bottom figure of FIG. 11C, when a lace tension threshold isachieved or exceeded, the force exerted by the lace tension and thewave-like configuration of the teeth, 1134 and 1146, causes the clutchcomponents 1106 to displace radially inward and out of engagement withthe teeth 1146 of knob 1110. Spring 1108 then functions to bias theclutch components 1106 back into engagement with adjacent teeth 1146 ofknob 1110. Further operation of the knob 1110 causes the clutchcomponent 1106 to continually displace radially inward and outward,causing the clutch components teeth 1134 to skip into and out ofengagement with the teeth 1146 of knob 1110. Counter-rotation of theknob 1110 will cause the lace tension to release or loosen.

In some embodiments, the clutch components 1106 may be incorporated intoa device or conventional closure system that is configured to tighten anarticle, such as a shoe. In such embodiments, the device may include ahousing having an interior region and a spool that is positioned withinthe interior region of the housing and rotatable relative thereto. Atightening mechanism, such as a knob, may be operably coupled with thespool to cause the spool to rotate within the interior region of thehousing. A tension member, such as lace, may be coupled with the spooland configured to be tensioned upon rotation of the spool via thetightening mechanism. The clutch components 1106 may function as a forcelimiting mechanism that is configured to transfer tightening forces fromthe tightening mechanism to one or more internal components of thedevice, such as the spool, until a tightening force threshold isachieved. As described above, the clutch components 1106 may be furtherconfigured to not transfer tightening forces from the tighteningmechanism to the one or more internal components of the device after thetightening force threshold is achieved.

As described herein, the clutch component may operationally engage witha spring that is positioned around a central protrusion or bushing. Thespring may bias the clutch component toward an engaged position in whichtightening forces are transferred to the one or more internalcomponents. The clutch component may radially engage with the knob viathe spring to transfer the tightening forces from the knob to the one ormore internal components until the tightening force threshold isachieved, after which the clutch component may radially disengage fromthe knob so that the tightening forces are not transferred from the knobto the one or more internal components. The spring may be configured tomaintain the device in an open position in which the tension member'stension is released or loosened. In some embodiments, the knob may bepulled axially upward and the spring may flex around the centralprotrusion or bushing to maintain the device in the open configuration.The clutch component may be positioned within a void or cavity axiallybelow the knob.

Referring now to FIGS. 12A-E, illustrated is another embodiment of adevice or closure system 1200 having a tension limiting component ormechanism. As shown in the exploded perspective view of FIG. 12B, system1200 includes a housing 1202 having an interior region and a pluralityof housing teeth 1230. In some embodiments the housing 1202 may have anopen top end and an open bottom end while in other embodiments thehousing 1202 may have a closed bottom end. A spool 1204 is positionedwithin the interior region of the housing 1202 and is rotatable relativethereto. Spool 1204 includes an annular channel (not numbered) aroundwhich a tension member or lace (not shown) is wound to tension thetension member. Spool 1204 also includes a plurality of axially orientedteeth 1232 that engage with corresponding axially oriented teeth 1234 ofa core 1206 positioned axially above the spool 1204. Engagement of theteeth, 1232 and 1234, transfers rotational forces between the twocomponents.

A plurality of pawl components 1208 are operationally coupled with thecore 1206. Each pawl component 1208 includes pawl teeth 1236 that engagewith the housing teeth 1230 of housing 1202 in a ratchet like fashion toallow the spool 1204 to be rotated within the housing's interior regionin a first direction while preventing rotation of the spool 1204 in asecond and opposite direction. In some embodiments, the core 1206 andpawl component 1208 may be replaced by a single component, such as apawl disc. In other embodiments, the arrangement of the various teethmay be different. For example, radially oriented teeth may have an axialorientation and/or axially oriented teeth may have a radial orientation.In some embodiments, housing teeth 1230 may be replaced by a toothedcomponent or disc that couples with the housing 1202.

A spring component 1210 is positioned axially above the pawl components1208. Spring 1210 is similar to spring 1108 described above. Spring 1210couples with a central bushing 1212 and is configured to maintain thesystem 1200 in an open configuration. System 1200 can be positioned inthe open configuration by pulling axially upward on a knob component1226, by pressing a button (not shown), by counter-rotating the knobcomponent 1226 by a defined amount (e.g., ¼ to ½ counter-rotation), andthe like. In some embodiments, spring 1210 may be replaced with a washeror other component having two or more stable positions, A screw or otherfastener 1214 may couple the various components together. A furtherdescription of these components is included in U.S. application Ser. No.13/098,276, which is incorporated by reference herein.

A cap component 1220 is positioned axially above the previouslydescribed components. The cap component 1220 is configured so that thecore 1206 may couple with the cap component 1220. For example, variousfeatures of the core 1206 may snap into engagement with the capcomponent 1220 to couple the two components together. Because the core1206 and cap component 1220 snap into engagement, or otherwise coupletogether, rotational forces input to the cap component 1220 aretransferred to the core 1206. A toothed disc 1222 couples with the capcomponent 1220, such as by snapping together. The toothed disc 1222includes radially inward oriented drive teeth 1242 that engage withcorresponding radially outward oriented drive teeth 1240 of capcomponent 1220. Engagement of the drive teeth, 1242 and 1240, aids intransferring rotational forces between the two components.

A drive disc 1224 is positioned axially above the toothed disc 1222.Drive disc 1224 includes a pair of cantilevered arms 1254 that extendcircumferentially from a main body of the disc 1224. Each cantileveredarm 1254 includes a tooth 1248 positioned on a distal end that ispositioned within a corresponding axially oriented tooth 1250 or notchof toothed disc 1222. Engagement of the teeth, 1248 and 1250, of disc1224 and 1222, respectively, transfers rotational forces between the twocomponents. As described in greater detail below, the cantilevered arms1254 are configured to axially flex when the tension threshold isachieved or exceeded to prevent further tensioning of the tension memberor lace. Although FIG. 12B illustrates drive disc 1224 having a pair ofcantilevered arms 1254 that each include axially oriented teeth 1248, itshould be realized that in other embodiments more or fewer arms 1254 maybe used. For example, in some embodiments, disc 1224 may include asingle cantilevered arm 1254 or three or more cantilevered arms.Similarly, some or all of the arms 1254 could include radially orientedteeth that cause the arms to flex radially inward and outward.

As described in greater detail below, the drive disc 1224 and tootheddisc 1222 function as a tension limiting mechanism that allows thetension member or lace to be tensioned via a tightening mechanism (e.g.,knob component 1226) until a tension threshold is achieved, after whichfurther operation of the tightening mechanism does not substantiallytension the tension member or otherwise cause further tensioning of thetension member.

The knob component 1226 is positioned axially above the drive disc 1224.Knob component 1226 functions as a tightening mechanism that may begrasped and rotated by a user to tension the tension member or lace.Knob component 1226 is operably coupled with the spool 1204 via one ormore of the components previously described. Rotation of the knobcomponent 1226 causes the spool 1204 to rotate within the interiorregion of the housing 1202, which winds the tension member or lacearound the spool's annular channel and thereby tensions the tensionmember or lace. Knob component 1226 also includes indicia 1260 thatindicates the tension threshold of the system 1200 that may be setand/or adjusted as described below.

A fastener 1228, such as a screw, may be coaxially aligned with andinserted through an aperture of the knob 1226. The fastener 1228 maythreadingly couple with a boss 1262 of cap component 1220 to couple thevarious component of system 1200 together. FIG. 12A shows an assembledperspective view of the system 1200 and FIG. 12C shows a cross sectionview of the assembled system.

FIG. 12E shows a bottom perspective view of the knob component 1226 anda top perspective view of the drive disc 1224 and toothed component1222. The bottom perspective view of the knob component 1226 shows atorque control member 1252 that is positioned on a bottom inner surfaceof the knob component 1226. The torque control member 1252 is used toadjust the tension threshold of the system 1200 by adjusting theflexibility of the cantilevered arms 1254. Specifically, the torquecontrol member 1252 is a flange or other axially protruding member thatis configured to be positioned atop the cantilevered arms 1254. Asdescribed previously in relation to FIGS. 8FF and 8GG, the position ofthe torque control member 1252 relative to the cantilevered arms 1254varies the moment arm and bending moment of the arms 1254 and thus,varies the tension threshold in which the system 1200 will no longertension the tension member or lace.

For example, when the torque control member 1252 is positioned near theproximal end of the arms 1254 and away from the tooth 1248, the flex ofthe arms 1254 is increased due to an increased moment arm and bendingmoment. This configuration allows the tooth 1248 to more easily deflectout of the notches 1250 of toothed disc 1222. As such, thisconfiguration requires a relatively low tension threshold before furtheroperation of the knob component 1226 will no longer tension the tensionmember or lace. In contrast, when the torque control member 1252 ispositioned near the distal end of arms 1254 adjacent the tooth 1248, theflex of the arms 1254 is greatly decreased due to a decreased moment armand bending moment. This configuration requires an increased inputtorque and/or lace tension force to cause the tooth 1248 to deflect outof the notches 1250 of toothed disc 1222. As such, this configurationrequires a relatively high tension threshold before further operation ofthe knob component 1226 will no longer tension the tension member orlace. In some embodiments, the torque control member 1252 may bepositioned axially above the teeth 1248 to prevent the teeth 1248 fromdeflecting out of the notches 1250. In this configuration, slippage ofthe drive disc 1224 and toothed disc 1222 may be essentially prevented.As such, this configuration ensures that operation of the knob component1226 will essentially always tension the tension member or lace.

In some embodiments, a radial inward end of the torque control member1252 may be positioned within radial grooves 1258 that are angularlypositioned on the main body of the drive disc 1224. In some embodiments,the radial grooves 1258 may be relatively evenly spaced about the mainbody between an angle of between about 90 and 150 degrees. The radialgrooves 1258 may be positioned so that a first radial groove ispositioned near the proximal end of the cantilevered arms and a lastradial groove is positioned near a distal end of the cantilevered armsadjacent the tooth 1248.

The position of the torque control member 1252 relative to thecantilevered arms 1254 may be changed by moving the knob component 1226axially upward relative to the drive disc 1224 and repositioning thetorque control member 1252. within a different radial groove 1258. Insome embodiments the drive disc 1224 may include approximately 8 radialgrooves that allow a user to set or vary the system 1200's tensionthreshold between 1 of 8 settings from a relatively low tensionthreshold to a relatively infinite threshold. In other embodiments thedrive disc 1224 may include more or fewer radial grooves 1258 asdesired. The indicia 1260 of knob component 1226 may correspond to theradial grooves 1258 to show the set tension threshold.

FIG. 12D illustrates the interaction of a tooth 1248 of the cantileveredarms and a notch 1250 of the toothed disc 1222. Specifically, the tooth1248 engages with the notch 1250 and transfers a rotational forcebetween the drive disc 1224 and toothed disc 1222. until the tensionthreshold is achieved or exceeded. After the tension threshold isachieved or exceeded, further rotation of the knob component 1226 causesthe cantilevered arm 1254 to flex, which causes the tooth 1248 toaxially deflect upward and out of the notch 1250. In this manner,rotation of the knob component 1226 causes the tooth 1248 to sequentialskip of flex into and out of engagement with adjacent notches 1250 ofthe toothed component 1222, thereby preventing or limiting furthertensioning of the tension member or lace via operation of the knobcomponent 1226. In some embodiments, the drive component 1224 andtoothed component 1222 may similarly operate when the knob component1226 is counter-rotated.

In some embodiments, the system 1200 may also include a controlmechanism that allows the tension member's tension to be substantiallymaintained upon tensioning of the tension member from a source otherthan the tightening mechanism. As used herein, the description of thetension member's tension being substantially maintained means that thetension member's tension is not substantially or significantlyincreased. The description may also mean that the tension member'stension is loosened to some degree. Likewise, the description of thetension member being tensioned from a source other than the tighteningmechanism means that some other factor or component is causing anincrease in the tension member's tension.

For example, in shoe applications, the tension member's tension may beincreased as the user flexes their foot, engages in a sporting event,runs, walks, and the like. In such applications, the tension may also beincreased due to swelling of the foot. In such embodiments, the controlmechanism may function to prevent the tension member from being furthertensioned. This tension limitation may be important to prevent injury toa body part, such as the development of ulcers in diabetic individualsdue to swelling of the feet.

In some embodiments, the control mechanism may be disposed axially belowa load holding element (e.g., pawl components 1208) that allows rotationof the spool in a first direction while preventing rotation of the spoolin a second direction. This configuration is represented in previouslydescribed FIG. 6. In some embodiments, the control mechanism may have anon-linear bottom surface that frictionally engages with a non-lineartop surface of the spool to transfer rotational forces between thecontrol mechanism and spool and thereby tension the tension member untilthe tension threshold is achieved. The non-linear surfaces may alsoallow slippage of the spool relative to the control mechanism after thetension threshold is achieved so as to limit additional tensioning ofthe tension member. In such embodiments, the bottom surface of thecontrol mechanism and the top surface of the spool may have a wave-likeor sinusoidal shape as described above. In other embodiments, thenon-linear bottom surface of the control mechanism and the non-lineartop surface of the spool may be configured to frictionally engage asdescribed above.

In some embodiments, the control mechanism may be a mechanism that isseparate from the tension limiting mechanism, while in other embodimentsthe tension limiting mechanism and the control mechanism are the same.In embodiments where the control mechanism is separate from the tensionlimiting mechanism, the control mechanism may allow the spool 1204 toslip at a higher tension threshold then the tension limiting mechanism.This may be preferred in instance where greater tensions are preferred,but prevention of over-tensioning is still desired. For example, indiabetic shoes it may be preferred to allow some increase in the tensionmember's tension to prevent the shoes from becoming loose due to walkingor running, while still preventing over-tensioning of the shoes fromswelling. In some embodiments, the tension limiting mechanism may bedisposed axially above the load holding element.

In some embodiments, a method for assembling a device for tightening anarticle may include providing a housing having an interior region andpositioning a spool within the interior region of the housing so thatthe spool is rotatable relative to the housing. The method may alsoinclude operably coupling a tightening mechanism with the spool so thatthe spool is rotatable within the interior region of the housing uponoperation of the tightening mechanism and coupling a tension member withthe spool so that the tension member is tensionable upon rotation of thespool via the tightening mechanism. The method may further includeoperably coupling a tension limiting mechanism with the spool to enablethe tension member to be tensioned via the tightening mechanism until atension threshold is achieved, after which further operation of thetightening mechanism does not substantially tension the tension member.

In some embodiments, the method may additionally include providing thetightening mechanism with an indicator having indicia representative ofa set tension threshold. In some embodiments, the method mayadditionally include coupling a control mechanism with the spool wherethe control mechanism is configured to allow the tension member'stension to be substantially maintained upon tensioning of the tensionmember from a source other than the tightening mechanism. In suchembodiments, the control mechanism may be disposed axially below a loadholding element that allows rotation of the spool in a first directionwhile preventing rotation of the spool in a second direction.

Having described several embodiments, it will be recognized by those ofskill in the art that various modifications, alternative constructions,and equivalents may be used without departing from the spirit of theinvention. Additionally, a number of well-known processes and elementshave not been described in order to avoid unnecessarily obscuring thepresent invention. Accordingly, the above description should not betaken as limiting the scope of the invention.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassed.The upper and lower limits of these smaller ranges may independently beincluded or excluded in the range, and each range where either, neitheror both limits are included in the smaller ranges is also encompassedwithin the invention, subject to any specifically excluded limit in thestated range. Where the stated range includes one or both of the limits,ranges excluding either or both of those included limits are alsoincluded.

As used herein and in the appended claims, the singular forms “a”, “an”,and “the” include plural referents unless the context clearly dictatesotherwise. Thus, for example, reference to “a process” includes aplurality of such processes and reference to “the device” includesreference to one or more devices and equivalents thereof known to thoseskilled in the art, and so forth.

Also, the words “comprise,” “comprising,” “include,” “including,” and“includes” when used in this specification and in the following claimsare intended to specify the presence of stated features, integers,components, or steps, but they do not preclude the presence or additionof one or more other features, integers, components, steps, acts, orgroups.

What is claimed is:
 1. A reel for use with a lacing system fortightening an article comprising: a housing having an interior region; aspool positioned within the interior region of the housing and rotatablerelative thereto, the spool having an annular channel formed therein; aknob rotatable relative to the housing and operably coupled with thespool to cause the spool to rotate within the interior region of thehousing; a tension member coupled with the spool so as to be tensionedby winding the tension member around the spool's annular channel uponrotation of the knob; a tension control mechanism that is configured toenable tensioning of the tension member by rotation of the knob until atension threshold is achieved, after which further rotation of the knobdoes not cause further tensioning of the tension member; and anadjustment mechanism that is operably coupled with the tension controlmechanism and that is adjustable by a user to adjust the tensionthreshold upon which further rotation of the knob does not cause furthertensioning of the tension member.
 2. The reel of claim 1, wherein theadjustment mechanism includes an adjustment arm or member that isrotatable by the user to adjust the tension threshold.
 3. The reel ofclaim 1, wherein the tension control mechanism is further configured toenable rotation of the spool within the housing's interior region upontensioning of the tension member from a source other than the knob. 4.The reel of claim 1, wherein the tension control mechanism comprises anon-linear clutch mechanism that transfers a rotational force from theknob to the spool until the tension threshold is achieved, and whereinthe non-linear clutch mechanism allows slippage of the spool after thetension threshold is achieved to limit additional tensioning of thetension member.
 5. The reel of claim 4, wherein the non-linear clutchmechanism has a wave-like or sinusoidal shape.
 6. The reel of claim 1,wherein the adjustment mechanism includes a spring member that biases afirst component of the tension control mechanism toward a secondcomponent of the tension control mechanism, and wherein user adjustmentof the adjustment mechanism comprises varying a biasing force of thespring member.
 7. The reel of claim 6, wherein the adjustment mechanismfurther includes a lever arm that is rotatable by the user to vary thebiasing force of the spring member.
 8. The reel of claim 1, wherein thetension control mechanism comprises one or more cantilever arms thatextend from a main body of the tension control mechanism and that engagewith corresponding teeth of a spool driving mechanism to enabletensioning of the tension member by rotation of the knob until thetension threshold is achieved; and wherein the adjustment mechanismadjusts a flexibility of the one or more cantilever arms.
 9. The reel ofclaim 6, wherein the spring member is replaceable such that useradjustment of the adjustment mechanism comprises replacing the springmember with another spring member having a different spring constant.10. The reel of claim 6, wherein the adjustment mechanism furtherincludes a detent, and wherein user adjustment of the adjustmentmechanism comprises varying a position of the detent in relation to thespring member.
 11. A reel device for tightening an article comprising: ahousing having an interior region; a spool positioned within theinterior region of the housing and rotatable relative thereto; a knoboperably coupled with the spool to cause the spool to rotate within theinterior region of the housing; a tension member coupled with the spoolso as to be windable about the spool, the tension member beingconfigured to be tensioned upon rotation of the spool via the knob; anda tension limiting mechanism that allows the tension member to betensioned via the knob until a tension threshold is achieved, afterwhich further operation of the knob does not substantially tension thetension member; and an adjustment mechanism that is adjustable by a userto adjust the tension threshold.
 12. The reel device of claim 11,wherein the tension limiting mechanism is configured to allow thetension member's tension to be substantially maintained upon tensioningof the tension member from the article.
 13. The reel device of claim 12,wherein the tension limiting mechanism is disposed axially below a loadholding element that allows rotation of the spool in a first directionwhile preventing rotation of the spool in a second direction.
 14. Thereel device of claim 12, wherein the tension limiting mechanismcomprises a non-linear clutch mechanism that transfers rotational forcesbetween the tension limiting mechanism and spool until the tensionthreshold is achieved and that allows slippage of the spool relative tothe tension limiting mechanism after the tension threshold is achieved.15. The reel device of claim 14, wherein the tension limiting mechanismhas a wave-like or sinusoidal shape.
 16. The reel device of claim 11,wherein the adjustment mechanism includes an adjustment arm or memberthat is rotatable by the user to adjust the tension threshold.
 17. Thereel device of claim 11, wherein the tension limiting mechanism isdisposed axially above a load holding element that allows rotation ofthe spool in a first direction while preventing rotation of the spool ina second direction.
 18. The reel device of claim 11, wherein theadjustment mechanism includes a spring member, and wherein useradjustment of the adjustment mechanism comprises varying a biasing forceof the spring member.
 19. The reel device of claim 18, wherein thespring member biases opposing wave like or sinusoidal shaped members ofthe tension limiting mechanism into engagement.
 20. The reel device ofclaim 18, wherein the adjustment mechanism further includes a lever armthat is rotatable by the user to vary the biasing force of the springmember.
 21. The reel of claim 1, wherein the tension control mechanismis further configured to allow rotation of the spool within thehousing's interior region upon tensioning of the tension member from thearticle.
 22. The reel of claim 21, wherein the tension control mechanismcomprises: a first mechanism that enables tensioning of the tensionmember by rotation of the knob until the tension threshold is achieved;and a second mechanism that enables rotation of the spool upontensioning of the tension member from the source other than the knob.23. The reel device of claim 11, wherein the tension limiting mechanismis configured to allow rotation of the spool within the housing'sinterior region upon tensioning of the tension member from the article.